Apparatus and method for cold working profile forming of workpieces

Abstract

A method is described for manufacturing a profiled profile body by cold working a workpiece (1) with a longitudinal axis (Z) and, in a machining area (11), a for example cylindrical outer surface (11a) extending along the longitudinal axis (Z) and incorporating a profile (P). Here, the workpiece (1) is machined by a tool (2) in a number of successively performed reshaping engagements in which the tool (2) makes a rotational movement (R1) about the longitudinal axis (Z) and comes into contact with the machining area (11). The tool (2) is held in a tool holder (5; 5a1) rotatably about a tool axis (Q). The tool holder (5) is - attached to a rotating body (8) so as to be rotatable about a rotation axis (W) and driven to perform a rotational motion (R5) about the rotation axis (W); - It is driven to perform an orbital motion (R8) by the orbiting body (8). Here, the rotational motion (R1) of the workpiece (1) is synchronized with the orbital motion (R8) of the tool holder (5), and the rotational motion (R5) of the tool holder (5) is synchronized with the orbital motion (R8) of the tool holder (5). Also, the tool axis (Q) is different from the rotation axis (W).

Description

Technical Field

[0001] The present invention relates in particular to the field of manufacturing profiles in solid or hollow parts with rotational symmetry by cold working. The present invention relates to an apparatus and a method according to the preamble of the claims.

Background Art

[0002] Various methods for profile forming of solid or hollow parts by cold working are known from the prior art.

[0003] For example, a hollow part having a profile is provided in a single step by a non-profile sheet metal part that is reshaped by an apparatus comprising a number of tools that engage the sheet metal part and generate a profile gap when the sheet metal part is inserted into the apparatus and distributed over the circumference. A corresponding method for manufacturing a pot-shaped sheet metal part having an inner tooth part and / or an outer tooth part having teeth extending along the intermediate axis of the pot is known, for example, from German Patent Application Publication No. 102014002971.

[0004] The disadvantage of such methods is that they are not very flexible, for example, because changing the profile gap shape requires changing all the tools and reconfiguring for machining sheet metal parts with different diameters requires creating a new apparatus that is correspondingly adapted.

[0005] In other cold working methods, such as those described in International Publication No. 2005 / 075125, the workpiece is periodically machined in a hammering manner by a tool driven in a circumferential manner to form the profile. This method is very flexible in its application because it can be reconfigured for other products or modified in terms of product specifications with very little effort. Furthermore, this method enables the production of very long profiles, even when it requires significant reshaping of materials, such as teeth with large modules of solid material. On the other hand, in the method described in International Publication No. 2005 / 075125, due to the circumferential motion of the tool, it is not so easy to guide the profile formation towards the shoulder portion that protrudes significantly radially outward.

[0006] A method for enabling profile forming onto a workpiece up to near a shoulder projecting outward is known, for example, from International Publication No. 2007 / 009267. In the method described therein, a cylindrical thin-walled hollow part seated on an outwardly profiled mandrel is cold-worked to provide a profile extending substantially parallel to the longitudinal axis of the hollow part, by which at least one profile forming tool is constructed to act significantly on the hollow part from the radially outward side of the hollow part to the longitudinal axis. In this specification, the profile forming tool is made to act on the surface of the hollow part in either case by vibrating in a direction perpendicular to the longitudinal axis and thus reciprocating linearly in the radial direction. Given a constant radial feed depth, the profile forming tool is displaced axially relative to the hollow part until a desired profile length is achieved, and machining of the hollow part can be started at the shoulder projecting outward.

[0007] When particularly high requirements for surface quality are given, it may be necessary to perform post-processing of the hollow part after the method described in International Publication No. 2007 / 009267. This is because the hollow part may be machined only in the short axial cross-section by the profile forming tool with each engagement, which may result in slight flaky roughness.

[0008] Furthermore, International Publication No. 2020 / 099536 provides a method for manufacturing profiles very close to shoulders that protrude significantly radially outward. This method also enables the manufacture of profiles, for example, in the case of teeth with large modules, especially when large pieces of solid material need to be reshaped. Moreover, this method can achieve high surface quality, and in principle does not require post-processing; however, at least in the case of solid materials, if high quality is required for profile molding, the length of the profile manufactured in this way is very limited anyway. [Overview of the Initiative] [Problems that the invention aims to solve]

[0009] The object of the present invention is to provide a method for manufacturing a profile body provided with a profile, and a corresponding apparatus that does not have the aforementioned drawbacks.

[0010] For example, it becomes possible to easily and inexpensively modify a method or apparatus to manufacture or implement the specifications of other products.

[0011] A further possible object of the present invention is to enable the creation of profiles having particularly high surface quality.

[0012] A further possible object of the present invention is to manufacture long-length profiles, particularly in relation to profile molding that requires significant reshaping of materials, such as teeth having large modules, especially of solid materials.

[0013] A further possible object of the present invention is to enable particularly accurate profile molding, especially in solid materials and when a large profile length is given.

[0014] A further possible objective of the present invention is to enable profile creation with particularly high productivity.

[0015] A further possible object of the present invention is to enable profile forming up to near the workpiece protrusion, for example, near the shoulder portion that protrudes outward from the workpiece being profiled.

[0016] A further possible object of the present invention is to enable profile molding between and near two profile defining structures. [Means for solving the problem]

[0017] At least one of these objectives can be achieved by the apparatus and / or method described below.

[0018] In this method, a tool holder, and a tool held by the tool holder having it, are driven to perform a complex motion involving at least two components, specifically, orbital motion along a circumferential path similar to that of a planet, and rotational motion about its own axis. Here, these two motions are synchronized with each other. The orbital motion may be periodic motion. A suitable drive mechanism can be provided to generate the rotational motion.

[0019] Through the rotational motion, the tool holder and tool are also periodically guided to the workpiece being machined, act upon it in a reshaping manner, and then move away from the workpiece again to approach it once more. For example, the tool can reshape-engage with the workpiece once per rotation (or every two or three rotations).

[0020] The rotational motion of the tool axis around the rotation axis of the tool holder, along with the circumferential motion of the tool holder, is provided, as will be described in more detail below, so that the tool can repeatedly machine a workpiece using a cold working method in a novel way. The tool may have an active region that repeatedly machines the workpiece within the machining area of ​​the workpiece. Here, the direction of rotation of the tool holder around the rotation axis may, in particular, be opposite to the direction of rotation of the circumferential motion.

[0021] The method is similar to that described in International Publication No. 2005 / 075125, but the important difference between the methods arises from the difference between the tool axis and the tool holder rotation axis (which are identical in International Publication No. 2005 / 075125), as will become clear later.

[0022] Therefore, in either case, the engagement of the tool with the workpiece during a short duration can occur periodically (due to circumferential motion) and within this short duration in which the tool (more precisely, the active area of ​​the tool) is in contact with the workpiece, and in some cases the tool can rotate not only around the tool axis but also around the rotation axis of the tool holder, and as a result, in addition to the circumferential motion provided by the tool holder (during the aforementioned short duration), the motion of the tool that can counteract the circumferential motion is added. Thus, the length of the contact area in which the active area of ​​the tool contacts the workpiece during reforming engagement can be shorter than in the case of the method described in International Publication No. 2005 / 075125 above. Furthermore, this is clearly different from non-hammering, such as the rolling machining known from International Publication No. 2020 / 099536 above.

[0023] The machining of the workpiece for shaping the profile consists of a number of individual machining steps along the axial extension of the profile, and the steps are axially offset from each other and only slightly overlap each other. Therefore, a high surface quality, especially a high accuracy of profile shaping, can be achieved. Thus, post-processing such as may be required in the case of the method according to WO 2007 / 009267, where the requirements for surface quality are particularly high, can be avoided.

[0024] With the above synchronization, when the tool holder rotates about its own axis, when the tool engages with the workpiece, the tool holder can be positioned in a desired or predetermined azimuth alignment, for example, always in the same azimuth alignment. Due to the above rotational movement, a change in the azimuth alignment of the tool holder occurs during each engagement. For example, the azimuth alignment of the tool holder with each engagement changes in the same way over the duration of the engagement.

[0025] For example, the rotational movement of the tool holder can be synchronized with the circumferential movement of the tool holder such that the tool holder passes through the same azimuth orientation for each of the reforming engagements.

[0026] In this specification, the terms azimuth and azimuthally relate to the axis of rotation of the tool holder, unless otherwise specified.

[0027] The synchronization enables the useful application of tools rotatably mounted about a tool axis different from the above-mentioned axis of rotation. In particular, tools having a rotationally symmetric active region can be applied. Thus, the tool can be, for example, a roller as known, for example, from WO 2005 / 075125 mentioned above.

[0028] During the rotation of the tool axis about the axis of rotation, due to the inherent rotation of the tool holder about its axis of rotation, the tool after engagement can break away from the workpiece relatively quickly again. As a result, contact with workpiece protrusions, such as workpiece shoulders, can be avoided, and thus reshaping of the workpiece protrusions by the tool can be avoided.

[0029] To achieve the desired axial extension of the profile, an axial advancement of the workpiece can be provided.

[0030] For example, the rotational movement can be performed during a full revolution or continuously. Thereby, a good synchronization ability between the rotational movement of the tool holder and the circumferential movement of the tool holder can be achieved.

[0031] For example, the synchronization of the two movements can be achieved mechanically. Therefore, a mechanical synchronization device can be provided for this synchronization. However, the above-described movements can be synchronized with each other in different ways, for example electronically, and thus by an electronic synchronization device.

[0032] In some exemplary embodiments, the above-described synchronization device, also referred to hereinafter as the second synchronization device, comprises a planetary gear. For example, it can comprise a ring gear and planetary gears running within the ring gear. The planetary gears can represent a part of the tool holder, or can be fixedly connected to at least the tool holder, or can co-rotate about the axis of rotation together with the rotational movement of the tool holder and also participate in the above-described circumferential movement. The axis of the planetary gear may be coaxial with the axis of rotation.

[0033] On the other hand, the planetary gear can also drive the tool holder for its rotational movement about its axis of rotation. Therefore, the drive device for generating the rotational movement of the tool holder about the axis of rotation of the tool holder, which has already been described above, can comprise a planetary gear.

[0034] This makes it possible to provide a planetary gear that simultaneously generates rotational motion around the rotation axis of the tool holder and synchronizes this rotational motion with the orbital motion of the tool holder.

[0035] As described above, for example, planetary orbital motion can be imparted to the tool holder by an orbiting body. The tool holder can be attached to the orbiting body, and in particular, it can be attached so as to be rotatable about its axis of rotation. The orbiting body can perform rotation, for example, about its axis, and the axis of rotation of the tool holder is at a distance from the axis of rotation, so that the axis of rotation performs orbital motion along an essentially circular path.

[0036] If the aforementioned planetary gear is assumed, this circumferential motion can generate rotational motion of the tool holder provided by the planetary gear. For this purpose, the axis of the circumferential body can be aligned coaxially with the axis of the ring gear. Thus, the drive device for generating the rotational motion of the tool holder about its axis of rotation, as already described above, can comprise a circumferential body and a planetary gear. Similarly, the drive shaft while the circumferential body rotates about its axis can belong to the drive device described above.

[0037] In addition to the rotating body, the drive shaft used to drive the rotating body in its rotation around its axis can also be considered a drive device for generating the motion of the rotating body.

[0038] Furthermore, radial feed of the tool holder can be provided perpendicular to the longitudinal axis of the workpiece holder that holds the workpiece or tool, thereby enabling deeper engagement of the tool with the workpiece during the machining process. The tool holder can be advanced radially until the desired profile depth is reached.

[0039] For example, radial feeding can be achieved by the movement of a circumferential body, or at least the circumferential body axis of the circumferential body, toward the longitudinal axis, and thus in this context, it undergoes radial advancement.

[0040] For example, a circumferential body is mounted on a profile forming head so as to be rotatable about its axis, and in particular, mounted on a profile forming head, which is driveable to move toward the longitudinal axis. Thus, while the circumferential body rotates about its axis, it can be moved toward the longitudinal axis by a drive unit for radial feeding. Thus, the axis of the circumferential body can move toward the longitudinal axis.

[0041] This allows the aforementioned complex motion of the tool holder (and tool) to further include additional components, specifically the aforementioned motion extending radially with respect to the longitudinal axis (radial feed motion). Thus, the axis of rotation of the tool holder can perform motion resulting from circular motion superimposed on linear motion of the center point of a circle, the linear motion in particular occurring in a plane defined by the circular motion.

[0042] Furthermore, the rotational motion of the workpiece or workpiece holder around the longitudinal axis can be generated and provided, for example, by a suitable drive device, such as a torque motor, and as a result, the workpiece can be machined by tools at different positions distributed along the circumference of the workpiece. Thus, different profile gaps of the manufactured profile can be produced by tools. As will be further explained below, several tools can be provided, and as a result, a single tool (or each of the tools) does not necessarily contribute to shaping all the profile gaps of the profile. Nevertheless, it can be assumed that the tools engage with the workpiece at all positions along the circumference of the workpiece, at which positions profile gaps of the profile are generated and thus contribute to shaping all the profile gaps of the profile.

[0043] The rotational motion described above may have a changing rotational speed, particularly a rotational speed that changes at least partially periodically. The rotational motion described above may be, for example, intermittent rotation.

[0044] The rotational speed of the workpiece or workpiece holder can be assumed to have a series of stages of relatively high and relatively low rotational speeds. In particular, machining of the workpiece by the tool can be performed during each of the stages of relatively low rotational speed. The slower the workpiece rotates during tool engagement, or the slower the workpiece rotates, or the more it remains stationary at a relatively low rotational speed, the better the accuracy of the final produced profile can be achieved.

[0045] For example, one can imagine a tool that machines a workpiece during the rotational motion phase while the workpiece is stationary. For example, one can imagine a tool that machines a workpiece during the phase where the intermittent rotation of the workpiece has stopped (the rotational speed at the time of stopping is 0).

[0046] On the other hand, it is also possible to assume the aforementioned rotational motion having a constant rotational speed. As a result, productivity can be improved.

[0047] This allows for synchronization of the rotational motion of the workpiece holder and the circumferential motion of the tool holder. This ensures that the workpiece is repeatedly machined at the same position along its circumference.

[0048] For example, each of the synchronous devices, also referred to as the first synchronous device below, can be an electronic synchronous device.

[0049] In the embodiments outlined above, using planetary gears and a rotating body, the first synchronization device can synchronize, for example, the drive for the rotation of a workpiece or workpiece holder with a drive shaft for driving the rotating body to rotate about its axis.

[0050] Therefore, this method can be used in particular to manufacture a profile body with a profile formed by cold working a workpiece, the workpiece may have a longitudinal axis and an outer surface within the machining area into which the profile is incorporated. The outer surface may extend along the longitudinal axis. In particular, the outer surface may be concentric with the longitudinal axis, for example, conical or cylindrical. However, other shapes of the outer surface, such as polygonal shapes, for example, a predetermined prism machining area, are also possible.

[0051] Here, the workpiece performs rotational motion around its longitudinal axis. Furthermore, the workpiece, particularly its outer surface as described above, is machined by the tool in a series of sequentially performed reshaping engagements, during which the tool, or more precisely, the active area of ​​the tool, comes into contact with the machining area. Each of these tool movements is described further above.

[0052] The tool is held by a tool holder, which is mounted on a rotating body so as to be rotatable about the tool holder's axis of rotation and is driven to rotate about that axis. The tool holder is driven to rotate by the rotating body. Specifically, the tool holder is driven by the rotating body to move along a circular path.

[0053] The tool is mounted in the tool holder so as to be rotatable around the tool axis, and the tool axis is not the same as the axis of rotation of the tool holder.

[0054] In particular, the tool axis can be at a distance from the rotation axis of the tool holder. The two axes can be aligned parallel to each other, for example. In the general case, including axes that are not aligned parallel to each other, "distance" means that the axes, which are mathematically understood as straight lines, do not intersect.

[0055] Comparing the method described herein with the method in the aforementioned International Publication No. 2005 / 075125, it can be seen that given substantially the same diameter of the circumferential body, substantially the same amount of force is available for reshaping, thereby enabling significant reshaping even with solid materials and large tooth-forming modules when a larger diameter is given. However, in the method described herein, the length of the tool's extension close to the workpiece (parallel to the axis of the workpiece holder or parallel to the direction of profile forming), for example, the length of the extension during which the tool (more precisely, the active area of ​​the tool) contacts the workpiece, can be shorter than in the case of the aforementioned International Publication No. 2005 / 075125. This is because, when the tool is mounted non-coaxially to the tool holder, the superposition of the circumferential motion and the rotational motion of the tool holder allows the tool's motion near the workpiece to be described as motion along a hypocycloid, such as an ellipse, which can be described as substantially circular motion near engagement, and the diameter of this circular motion can be substantially smaller than the diameter of the circumferential motion. Therefore, it is possible to generate a profile closer to the shoulder portion that protrudes outward from the workpiece being profiled, compared to the method described in International Publication No. 2005 / 075125, where the same circumferential motion is given.

[0056] However, profiles that are similarly close to the shoulder portion protruding outward from the workpiece being profiled can also be manufactured by the method described in the aforementioned International Publication No. 2005 / 075125. However, this only works if the circumferential diameter is selected to be correspondingly small, for example, as small as the diameter of the circular motion described above. However, this significantly reduces the force available for reshaping the workpiece, making it impossible to manufacture, for example, large tooth modules of solid material.

[0057] On the other hand, comparing the method described herein (using a sector tool) with the method from the aforementioned International Publication No. 2020 / 099536, it can be seen that here it is possible to generate a pseudo-arbitrary profile length and maintain a consistently good quality along the entire profile. In contrast, in the method according to International Publication No. 2020 / 099536, this is only the case for profile lengths that maximally correspond to the length of the active region of the sector tool. This is because the material behavior, in principle, the flow behavior of the workpiece material is not constant along the profile, and as a result it is almost impossible to maintain a narrow profile tolerance over a given long profile. For example, the material of a tubular workpiece at the end of the workpiece can deform and flow more easily than in the center of the workpiece. Therefore, the ability to apply the method using a sector tool according to International Publication No. 2020 / 099536 tends to be limited to short profiles.

[0058] In particular, a tool can be rotatable around its axis. Therefore, a tool can be rotated around its axis by engaging with a workpiece.

[0059] The tool may have an active region that is rotationally symmetric with respect to the tool axis. In this way, the result of engagement can be independent of the rotational direction of the tool with respect to the tool axis, which exists during engagement.

[0060] The tool can be materialized, for example, as a roller. Furthermore, the following can be considered:

[0061] - The rotational motion of the workpiece is synchronized with the rotational motion of the tool holder, and - The rotational motion of the tool holder is synchronized with the circumferential motion of the tool holder.

[0062] In particular, the rotational motion of the workpiece can be assumed to be synchronized with the circumferential moment of the tool holder so that several reshaping engagements occur at each of several different locations distributed around the circumference of the workpiece. When an outer profile is formed, the above-mentioned locations can be the locations where profile gaps of the profile are created. When an inner profile of the workpiece is formed by this method, the locations can be those located between adjacent profile gaps of the inner profile being formed.

[0063] Furthermore, it can be assumed that, in particular, for each reshaping engagement, the rotational motion of the tool holder is synchronized with the circumferential motion of the tool holder so that the tool passes through the same azimuthal orientation.

[0064] If the rotational motion of the tool holder is synchronized with the circumferential motion of the tool holder such that the azimuthal orientation through which the tool passes during each reshaping engagement is the same for each reshaping engagement, then it is possible to create profiles that extend close to profile-defining structures, such as protrusions on a workpiece.

[0065] Furthermore, for the advance shaping of the profile in the workpiece, we can consider the relative motion of the workpiece with respect to a circumferential body that is performed parallel to the longitudinal axis. In particular, as mentioned above, the circumferential body may have a circumferential body axis that rotates around it, and the relative motion of the workpiece with respect to the circumferential body axis is performed parallel to the longitudinal axis.

[0066] For example, a workpiece can be driven to move parallel to its longitudinal axis (axial advance).

[0067] Axial advancement allows tool engagement at different axial positions (relative to the longitudinal axis) during the process of this method. For example, a workpiece holder that holds a workpiece can be driven in a direction parallel to the longitudinal axis via a drive unit.

[0068] This method can also be viewed as a method for shaping a workpiece, and / or a method for shaping a profile onto a workpiece.

[0069] The workpiece can be a hollow component, particularly one that is rotationally symmetric, such as a cylindrical hollow component.

[0070] The workpiece can be a solid part, particularly one that is rotationally symmetric, such as a cylindrical solid part.

[0071] The workpiece can be a metal workpiece. The machining area can be the area in which profile forming is incorporated, and therefore the area that is profile-formed. The machining area can be a portion of the workpiece limited to the axial direction, for example, the end piece of a tubular or rod-shaped workpiece.

[0072] The workpiece may include a second region connected to the machining area. This second region adjacent to the machining area may include a profile defining structure, such as a workpiece projection, and has a radial extension that is larger than the radial extension of the outer surface of the machining area adjacent to the workpiece projection, at least in the angular region (azimuth angle) centered on the longitudinal axis. The profile defining structure may be a profile forming obstacle, such as a workpiece shoulder.

[0073] The profile definition structure can form the end or definition portion of the profile. The outer surface of the machining area can be, for example, rotationally symmetric, such as cylindrical or conical. However, the outer surface can also be designed to be different, such as polygonal.

[0074] The profile can be an outer profile. This can be created on a hollow or solid part. For example, with respect to a hollow part, if we assume that the workpiece within its machining area is seated on the mandrel of the outer profile, it is possible to form the outer and inner profiles simultaneously. Furthermore, it is possible to manufacture the inner teeth on a hollow part without simultaneously manufacturing the outer teeth. For this reason, we can assume that the workpiece within its machining area is seated on the mandrel of the outer profile.

[0075] Profile forming can involve a number of profile gaps (depths of the workpiece in the machining area) distributed circumferentially, particularly uniformly distributed circumferentially. However, profile gaps can be distributed circumferentially in a non-uniform manner.

[0076] The rotational motion of the tool holder can be continuous, and in particular, can be performed at a constant speed.

[0077] The rotational motion of the tool holder can be continuous, and in particular, it can be performed at a constant rotational speed.

[0078] In particular, these two velocities can have a constant temporal ratio to each other. Circular motion can be described as circular motion.

[0079] In particular, the trajectory (motion path) of the tool holder can be derived from a superposition of motion perpendicular to the longitudinal axis (radial direction) and orbital motion.

[0080] In some embodiments, the rotating body performs a rotation about its axis. This can generate the rotational motion of the tool holder. The rotational motion of the tool holder can be performed in a plane perpendicular to the axis of the rotating body.

[0081] The axis of rotation and the axis of circumference can be aligned parallel to each other. The direction of rotation of the tool holder's rotational motion (around the axis of rotation) can be, for example, opposite to the direction of rotation of the orbital motion (around the axis of the orbital body).

[0082] The rotational motion of the tool holder can be performed in a plane in which the longitudinal axes are aligned parallel to each other, and / or in a plane in which the plane perpendicular to the tool axis is perpendicular to the plane perpendicular to the longitudinal axis. In particular, this can be provided to generate a profile extending parallel to the longitudinal axis, such as a straight tooth section, especially when the rotational motion of the workpiece or workpiece holder is reduced or intermittent rotational motion is provided during engagement.

[0083] On the other hand, different alignments can be provided when the workpiece still rotates during engagement, for example, when angled teeth are manufactured, or when a constant rotational speed of the workpiece or workpiece holder is given. For example, a plane perpendicular to the tool axis can then be assumed, enclosing a pivot angle with respect to the longitudinal axis, where the pivot angle is not zero. This pivot angle can be selected, for example, depending on the angle of the profile or the rotational speed of the workpiece or workpiece holder during engagement.

[0084] The rotation of the orbiting body can be a continuous motion, and in particular, it can have a constant rotational speed. Similarly, the rotational motion of the tool holder can be a continuous motion, and in particular, it can have a constant rotational speed. Furthermore, these two rotational speeds can have a constant temporal ratio to each other. Synchronization of these two rotational speeds can be achieved, as already mentioned above, by, for example, planetary gears.

[0085] A planetary gear system can comprise a ring gear and planetary gears that travel within the ring gear. The planetary gears can be part of a tool holder and can perform rotational motion together. The position of the planetary gears can be fixed relative to the position of the tool axis.

[0086] The ring gear can be fixed within a profile molding head, particularly one that is rotatably mounted, to which a circumferential body is attached.

[0087] The profile forming head can serve as a bearing housing for receiving or mounting components of the apparatus. For example, - The rotating body can be mounted in a way that allows it to rotate, - A drive unit for the rotation of the circumferential body can be attached, - As long as it exists, A ring gear fixed to a profile molding head.

[0088] Furthermore, the profile molding head can be actively connected to a drive unit for radial feeding, such as a linear drive unit.

[0089] Two profile forming heads may also be provided, each comprising at least one tool, for example, a first tool in the first profile forming head and a second tool in the second profile forming head. These can be arranged, for example, mirrored with respect to a plane containing the longitudinal axis, and facing each other with respect to the longitudinal axis. Both tools can be embodied, for example, as rollers.

[0090] In particular, the two profile molding heads, including device components such as circulating bodies and ring gears, can be designed identically or manufactured according to the same specifications, and the motion of the device components proceeds in a manner mirrored with respect to a plane containing the longitudinal axis.

[0091] The orbital motions of the two mentioned tools may be different from each other, and in particular, they may be performed in a manner that is mirrored to each other with respect to the plane containing the longitudinal axis. Here, the orbital motions of the two tools described above can be performed within the same plane.

[0092] Therefore, the rotational motion of the first tool (first profile forming head) can be synchronized with the rotational motion of the second tool (second profile forming head) so that the reforming engagement of the two tools described above occurs simultaneously.

[0093] Due to its (mirror-image) symmetrical structure, the forces directed along the longitudinal axis essentially cancel each other out, thus keeping the mechanical load on the workpiece holder low.

[0094] Some tools may also be located elsewhere for other reasons, for example, within the same profile forming head. These can be designed in the same way, for example. The tools can be rollers, for example, rollers designed in the same way. If several tool holders are provided, these can also be designed in the same way.

[0095] On the other hand, a single tool holder can hold two or more tools, for example, such that their tool axes are uniformly distributed in the azimuthal direction with respect to the tool holder's axis of rotation.

[0096] For example, these tools can alternately reshape the workpiece during consecutive rotations.

[0097] This allows for extending the lifespan of individual tools. On the other hand, two or more tool holders may be provided, each holding (at least) one tool. The orbital motion of these tool holders may, for example, follow the same orbital path, and they may be uniformly distributed along the orbital path. For example, these tool holders may be uniformly distributed in the azimuth direction with respect to the axis of the orbital body.

[0098] For example, a single engagement with the workpiece can be performed for each rotation of the circulating body for each tool holder.

[0099] This increases the number of engagements per unit time (assuming the number of rotations of the rotating body is the same), and therefore enables faster machining of the workpiece. During the rotation period of the rotating body, N reshaping engagements can be performed, where N specifies the number of tool holders, each having at least one tool.

[0100] If N specifies the number of tool holders, each having n tools, and two equally constructed (e.g., mirrored) boss heads are provided, then machining of the workpiece can therefore be performed using 2·N·n tools.

[0101] The tools, or at least their active areas, can be manufactured, for example, according to the same specifications.

[0102] As explained, the tool can be a roller. In the active region, the tool may have a shape in a cross-section along the cross-sectional plane that corresponds to a negative value of the shape of the profile gap of the generated profile, and this cross-sectional plane passes through the active region and includes the tool axis. If the plane perpendicular to the tool axis is aligned perpendicular to the plane perpendicular to the longitudinal axis, then a tool can be envisioned that, in a cross-section perpendicular to the longitudinal axis passing through the active region during engagement, has a shape that corresponds to a negative value of the shape of the profile gap of the manufactured profile.

[0103] In particular, this can be provided if the profile has an outer profile or is an outer profile. Optionally, the inner profile may also be molded at the same time as the outer profile or not.

[0104] The active region can be rotationally symmetric with respect to the tool axis. The active region can be defined as the area of ​​the tool that is in (direct) contact with the workpiece. However, given each engagement, it can be assumed that only a portion of the active region will be in (direct) contact with the workpiece. Considering a tool mounted rotatably around its axis, the extent to which each engagement brings the active region into (direct) contact with the workpiece is essentially random.

[0105] When a tool as described is held by a tool holder, the tool axis can rotate in conjunction with the associated tool holder. Furthermore, if a planetary gear is provided as part of the tool holder, the relative position of the tool axis to the planetary gear can also remain constant.

[0106] The tool may be part of a tool insert of a tool holder, which can be fixed to at least one further part of the tool holder.

[0107] The apparatus can be used to manufacture a profile body with a profile formed on it by cold working a workpiece. For this purpose, the apparatus can be used - A workpiece holder that is rotatable about its longitudinal axis for holding the workpiece, - A drive device for generating rotational motion of a workpiece holder about a longitudinal axis, in particular a drive device in which the rotational motion is intermittent or has alternating periods of stopping and rotational motion, - A circular body, - A tool holder for holding a tool, in particular a tool holder that is mounted on a rotating body so as to be rotatable about an axis of rotation of the tool holder, - A drive device for generating rotational motion around the rotation axis of the tool holder, - A drive device for generating motion of a circular body, wherein the drive device can drive a tool holder to perform circular motion, particularly along a circular path.

[0108] Furthermore, the device - A first synchronization device for synchronizing the rotational motion of the workpiece holder with the circumferential motion of the tool holder, - The system may include a second synchronization device for synchronizing the rotational motion of the tool holder with the circumferential motion of the tool holder.

[0109] A tool holder may be equipped with a rotating bearing that defines a tool axis different from the tool holder's axis of rotation, so that the tool can receive the tool, and specifically, the tool can rotate around the tool axis. In particular, the tool may be rotatable around the tool axis.

[0110] In some embodiments, the device includes a tool mounted on a rotary bearing so as to be rotatable about the tool axis.

[0111] In particular, the following tools can be considered. - Having an active region that is rotationally symmetric with respect to the tool axis, and / or - This is materialized as Laura.

[0112] The drive mechanism for generating rotational motion around the rotation axis of the tool holder can be at least partially identical to the second synchronous mechanism. For example, the planetary gear already described can be part of this drive mechanism by converting the motion of the orbiting body into the rotational motion of the tool holder, and can be part of (or correspond to) the first synchronous mechanism by coupling the rotational motion of the tool holder into the orbital motion of the tool holder.

[0113] A drive mechanism for generating the motion of a circulating body may include, for example, a drive spindle. This may also be part of a drive mechanism for generating the rotational motion of a tool holder about its axis of rotation, provided, for example, by planetary gears.

[0114] The circumferential body can be mounted on a profile forming head, and in particular, can be mounted in a rotatable manner. It can also be driven by a drive unit for radial feeding motion toward the longitudinal axis. The drive unit may be, for example, a drive unit for the motion of the profile forming head moving perpendicular to the longitudinal axis.

[0115] The apparatus may be equipped with a drive mechanism for generating the motion of a workpiece holder parallel to the longitudinal axis. This allows tool engagement to be performed gradually at a position that is progressively away from the edge of the workpiece. This enables the shaping of a profile that progresses parallel to the longitudinal axis.

[0116] The first and second synchronous devices may be the same synchronous device, or they may be completely or partially different from each other.

[0117] The first synchronization device can be configured to ensure that the rotational frequency of the first tool holder's rotational motion is at a fixed (time-unchanging) ratio with respect to the rotational speed of the workpiece.

[0118] The second synchronization device can be configured to ensure that the rotational frequency of the first tool holder's rotational motion is at a fixed (time-unchanging) ratio with respect to the speed of the tool holder's rotational motion.

[0119] The apparatus can be configured so that cold working of a workpiece can be performed by a number of sequentially executed reshaping engagements. These may be engagements of the same tool or engagements of several tools.

[0120] Furthermore, the first synchronization device can be configured to synchronize the rotational motion of the workpiece holder with the circumferential motion of the tool holder, resulting in several reshaping engagements occurring at each of several different locations distributed around the circumference of the workpiece.

[0121] The apparatus can be configured such that the tool contacts the machining area in each of the reshaping engagements. In particular, the apparatus can be designed so that the active area (or more precisely, a portion of the active area) of the tool contacts the machining area in each of the reshaping engagements. Each tool (or more precisely, its active area or portion of the active area) can act on the outer surface (within the machining area) in a hammering manner, as used herein. The tool can act on the machining area in a cold working manner using each engagement portion.

[0122] Furthermore, the second synchronization device can be configured to synchronize the rotational motion of the tool holder with the circumferential motion of the tool holder, so that in each reshaping engagement of the tool, the tool axis passes through the same (smaller) region of azimuth position (with respect to the axis of rotation).

[0123] If several tools and one or more tool holders (each holding at least one of the tools) are assumed, the second synchronization device may be configured to synchronize the rotational motion of at least one tool holder with the orbital motion of each tool holder, so that each of the tool axes passes through the same (small) region of azimuthal position (with respect to the axis of rotation) in each of the reshaping engagements of each tool.

[0124] For example, if the profile to be formed has r profile gaps, and the apparatus has N tool holders, and its circumferential motion traces one identical circumferential path, the first synchronous apparatus can be configured such that, for example, the Nth duration of the circumferential motion is equal to the rth integer multiple of the duration of the rotational motion of the workpiece. This ensures that engagement occurs precisely at positions along the circumference of the workpiece where the profile gaps are generated. In particular, the first synchronous apparatus can be configured such that, for example, the Nth duration of the circumferential motion is equal to the rth duration of the rotational motion of the workpiece. This ensures that engagement occurs at each adjacent profile gap position.

[0125] The present invention includes an apparatus having features corresponding to the features of the described method, and conversely, a method having features corresponding to the features of the described apparatus.

[0126] Further embodiments and advantages should be derived from the dependent claims and drawings.

[0127] The subject matter of the present invention will be described in more detail below with reference to examples of embodiments and the accompanying drawings. [Brief explanation of the drawing]

[0128] [Figure 1] Apparatus for carrying out a method for cold working profile forming of a workpiece. [Figure 2A] A series of steps in a method. [Figure 2B] A series of steps in a method. [Figure 2C] A series of steps in a method. [Figure 2D] A series of steps in a method. [Figure 3] A tool holder having a tool, shown in a cross-section passing through its axis of rotation and tool axis. [Figure 4] Details of a planetary gear with planetary gears shown in Figure 3. [Figure 5] Details of a device having two profile molding heads with symbolized radial feed and axial advance. [Figure 6A] The circular path of the tool holder. [Figure 6B] A symbolic representation of radial feeding motion. [Figure 6C] The trajectory of the tool holder as a superposition of orbital motion and radial feed. [Figure 7] Details of a device having two profile molding heads, each equipped with three tool holders, each containing two tools. [Figure 8] A profile body with shoulders that protrude outward. [Figure 9] Details of the workpiece on the mandrel of the outer profile in a cross-section perpendicular to the longitudinal axis. [Figure 10] A workpiece having a conical machining area, as shown in a cross-section including the longitudinal axis. [Figure 11] A workpiece having a polygonal outer surface, shown in cross-section perpendicular to the longitudinal axis. [Figure 12] A workpiece or profile body having a profile defining structure with two axially spaced and radially outward-facing profile definitions, in which a profile is formed. [Figure 13] A workpiece or profile body having two profile defining structures, radially inward and axially separated outward, with the profile formed in between. [Figure 14] Workpieces and profile bodies that do not have a profile definition structure. [Figure 15] A workpiece having a non-rotationally symmetric profile definition structure, shown in a cross-section perpendicular to the longitudinal axis. [Figure 16] A workpiece or profile body having profile gaps that are unevenly distributed in the azimuthal direction, as shown in a cross-section perpendicular to the longitudinal axis. [Figure 17] A schematic diagram of a situation where a pivot tool axis is given. [Modes for carrying out the invention]

[0129] Parts that are not essential to understanding the present invention are omitted from the illustrations. The examples of embodiments described are illustrative of the subject matter of the present invention or are useful in explaining it and are not limiting.

[0130] Figure 1 shows an apparatus 100 for carrying out a method for cold working profile forming of a workpiece 1. The workpiece 1 is held in a workpiece holder 10, which is symbolically represented in Figure 1 and has a longitudinal axis Z, which is also the longitudinal axis of the workpiece 1.

[0131] The illustrated example workpiece 1 is rotationally symmetric with respect to the longitudinal axis Z and includes a machining area 11 having an outer surface 11a, which is cylindrical in shape as an example, and incorporates a profile to which a second area 12 is connected, in which the workpiece 1 has a larger diameter than the machining area 11. This forms a profile-defining structure designed as the workpiece shoulder 13 between areas 11 and 12.

[0132] Furthermore, a circular body 8, symbolically represented in Figure 1, is provided. Specifically, in the illustrated example where the circular body rotates around a circular body axis not shown in Figure 1, it performs motion R8', and therefore rotation R8'. A tool holder 5 is attached to the circular body 8, which performs circular motion R8 along the circular path U by the motion R8' of the circular body 8.

[0133] The tool holder 5 is equipped with a rotation axis W, and around the rotation axis W, it performs a rotational motion R5. This rotational motion R5 can be generated directly, for example, by a drive unit (rotation drive unit), but can also be derived from the motion R8' of the orbiting body 8, for example, mechanically, for example, by a planetary gear, as will be described in more detail below.

[0134] The tool holder 5 holds at least one tool 2, the at least one tool 2 having an active region 21, in which it makes cold working contact with the workpiece 1 by performing motion during engagement with the workpiece 1, the motion of which will be described in more detail below. The tool 2 is rotatably mounted in particular within the tool holder 5 so as to be rotatable about the tool axis Q. The tool axis Q is not identical to the axis of rotation W of the tool holder 5. For example, it can be aligned parallel to it and at a distance from it.

[0135] Tool 2 may have an active region that is rotationally symmetric (with respect to the tool axis Q). Tool 2 can be embodied, for example, as a roller.

[0136] The profile gaps within workpiece 1 are generated by tool 2, and tool 2 performs multiple engagements for each profile gap.

[0137] To enable tool 2 to engage with workpiece 1 at different positions distributed around the circumference of workpiece 1, workpiece 1 can be driven by tool holder 10 to perform rotational motion R1 about the longitudinal axis Z, and in particular, rotational motion R1 can be intermittent rotation so that tool engagement occurs at each stopping stage of rotation of workpiece 1.

[0138] Furthermore, a drive unit can be provided for axial advancement of the workpiece 1 parallel to the longitudinal axis Z. This makes it possible to achieve forward forming of the profile along the longitudinal axis Z.

[0139] Active connections for driving purposes are shown by dashed lines in Figure 1, and active connections for synchronization purposes (which can be implemented mechanically and / or electronically) are shown by thick dotted lines.

[0140] A drive device A1, such as a torque motor or other rotational drive unit, is provided to generate the rotational motion R1 of the workpiece holder 10, and a drive device A8 is provided to generate the motion R8' of the circumferential body 8. The drive device A8 may include, for example, a drive shaft.

[0141] Furthermore, as already mentioned above, a drive device A5 is provided for generating a rotational moment R5 about the rotation axis W of the tool holder 5.

[0142] The axis of rotation W is aligned parallel to the axis of rotation. The rotational motion R8 of the tool holder takes place in a plane in which these axes are perpendicular. In the illustrated example, the longitudinal axis is aligned parallel to this plane.

[0143] The tool axis Q can be aligned parallel to the rotation axis W. In order for tool engagement to occur where a profile gap is generated, the workpiece rotation R1 and the circumferential motion R8 are synchronized with each other by a first synchronization device S1, for example by the workpiece rotation R1, and the motion R8' of the circumferential body 8 is synchronized with each other by the first synchronization device S1.

[0144] For example, synchronization can occur when two motions (R1 and R8 or R8') have a constant temporal ratio of their circumferential times. For instance, if only one tool 2 is provided, and in each case the continuous engagement of tool 2 with workpiece 1 occurs within adjacent profile gaps, then we can select T8 / T1=z, where T8 is the circumferential time (period) of the circumferential motion R8 of tool holder 5 and T1 is the circumferential time (period) of the workpiece, and z is the number of profile gaps generated.

[0145] This synchronization can be achieved, for example, by an electronic synchronous device S1. However, other synchronous devices, such as mechanical synchronous devices, are also fundamentally possible.

[0146] Furthermore, a second synchronization device S5 is also provided, which synchronizes the rotational moment R5 of the tool holder 5 with the orbital motion R8 of the tool holder 5. This can be achieved, for example, by an electronic synchronization device, in which case it may be the same as the first synchronization device S1. In the illustrated embodiment, this synchronization is achieved mechanically, specifically by the planetary gears already described.

[0147] To the extent of this, the drive unit A5 can be made at least partially identical to the second synchronous unit S5 by a planetary gear that generates rotational motion R5 on the one hand and achieves synchronization between rotational motion R5 and orbital moment R8 on the other hand.

[0148] The synchronization achieved by the second synchronization device S5 allows the tool axis Q to assume the same azimuthal alignment (with respect to the rotation axis W of the tool holder 5) during each engagement with the workpiece 1. This can be advantageous, for example, when the workpiece 1 has a workpiece shoulder 13 that protrudes outward, as shown in Figure 1, and the profile is formed up to near this shoulder. This is illustrated in Figures 2A to 2D.

[0149] Figures 2A to 2D show the sequential steps of this method. Most of the reference symbols have already been explained above. φ represents the azimuth position of the tool axis with respect to the rotation axis W, or more precisely, the corresponding azimuth angle (measured in the counterclockwise direction). For example, as shown in Figures 2A to 2D (and also in Figure 4, see below), the following can be selected as the reference axis for azimuth orientation.

[0150] - An axis that is aligned perpendicular to the axis of rotation W (shown as a dashed line in Figures 2A to 2D), passes through the center of the active region 21, and passes through the axis of rotation W, - An axis aligned perpendicular to the rotation axis W (shown as a dotted line in Figures 2A to 2D), passing through the center of the active region 21 and through the circumferential axis.

[0151] Figure 2A shows the situation immediately before engagement begins, after which tool 2 makes contact with workpiece 1. In the illustrated example, the azimuth angle φ is approximately 317°, which corresponds to -43°.

[0152] Figure 2B shows the situation during the engagement process. The azimuth angle φ is a few degrees in the example shown. Figure 2C shows the state immediately after engagement is complete. Tool 2 is no longer in contact with workpiece 1. The azimuth angle φ in the illustrated example is approximately 40°.

[0153] Figure 2D shows the situation after engagement is complete. Immediately thereafter, tool 2 moves over the shoulder portion 13 of the workpiece. The azimuth angle φ in the illustrated example is a good 70°.

[0154] The second synchronization device S5 allows, for example, the tool 2 to come into contact with the workpiece 1, and therefore, in each rotation, it can be reshaped in a hammering manner only in a small azimuth angle region close to 0°.

[0155] Due to the overlap of the circumferential motion of the tool holder and the rotational motion of the tool holder around the axis of rotation, tool 2 can only come into contact with workpiece 1 for a very short time and along a very short portion (for example, measured parallel to the longitudinal axis Z) because the tool axis and the axis of rotation are not the same.

[0156] Therefore, it is possible to prevent tool 2 from coming into contact with (reshaping) the workpiece shoulder 13, but nevertheless, the shaping of the profile can be carried out close to the workpiece shoulder 13.

[0157] As can be easily seen in Figure 2A, the end workpiece 1 shown on the right side may, instead of ending there, have a further workpiece projection (shown by a dotted line in Figure 2A). In such a case, it is possible to form a profile between the two workpiece projections so as to extend near each workpiece projection by the method described.

[0158] Figure 3 shows a tool holder 5 with a tool 2 in cross-section through its rotation axis W and tool axis Q. It comprises (optionally) two planetary gears 45 whose axes are coaxial with the rotation axis W, and two bearing regions 2L for rotatable mounting within the orbital body 8 (see Figure 1). The tool holder 5 can be designed as a single part or from several parts, as shown.

[0159] The tool holder 5 may include, for example, a tool insert 2e (shown in hatching in Figure 3 for improved visibility) on which a tool 2 is rotatably mounted about the tool axis Q. For example, as shown in Figure 3, a roller as the tool 2 can be mounted rotatably about the tool axis Q. For this purpose, the tool insert 22e may include a rotating bearing (not shown separately in the figure). The tool insert 2e can be fixedly connected to at least one further part of the tool holder 5, for example, by screwing it thereto.

[0160] The tool axis Q can be fixedly positioned within the tool holder 5 relative to the planetary gear 45.

[0161] Figure 4 shows, for example, a detailed cross-sectional view perpendicular to the rotation axis W of a device equipped with a planetary gear 45 integrated into the tool holder 5 shown in Figure 3, but only one side is visible in Figure 4.

[0162] The planetary gear 40 comprises a ring gear 41 having a shaft 42, and separately, although not shown in Figure 4, it may further comprise a second ring gear on which the second planetary gear of the tool holder 5 runs.

[0163] The axis 46 of the planetary gear 45 is coaxial with the rotation axis W. Also, the axis V of the circulating body (corresponding to the axis of the circulating motion of the tool holder) is coaxial with the axis 42 of the ring gear 41.

[0164] By appropriately dimensionalizing the planetary gear 40, it is possible to ensure that the tool axis Q at a specific position along the circumferential path U (see Figure 1) of the tool holder 5, where engagement with the workpiece 1 is completed or initiated, always has the same azimuth position (relative to the axis of rotation) for each rotation.

[0165] Instead of a planetary gear having two ring gears and two planetary gears, a planetary gear can also be implemented, for example, with one or fewer ring gears and one or fewer planetary gears.

[0166] When the two tool engagements, along with each tool engagement, are located at the same position on the workpiece 1, specifically facing each other with respect to the longitudinal axis, and especially facing each other axially (with respect to the longitudinal axis Z), the mechanical requirements on the workpiece holder 10 can be significantly reduced.

[0167] Figure 5 shows details of the apparatus 100 having two profile forming heads 3a and 3b, with radial feed and axial advance further symbolized. A rotating body (in each case including at least one tool holder) and planetary gears, provided they are provided, can be mounted on the profile forming heads 3a and 3b.

[0168] The profile molding heads 3a, 3b, or the parts attached thereto, can be designed in essentially the same way, but can be mirror images with respect to motion.

[0169] As a result, in all cases, the workpiece 1, indicated by the symbol in Figure 5 (dashed line), can be machined by two tools positioned opposite each other with respect to the longitudinal axis Z.

[0170] Therefore, the motion of the two orbiting bodies can be synchronized with each other, or they can result from the same motion of, for example, one identical rotational drive unit. Furthermore, one or more ring gears can be fixed to each of the profile molding heads.

[0171] In the machining process, it may be advantageous to be able to move the workpiece axially, and therefore parallel to the longitudinal axis Z, in order to enable the advance forming of the profile along the longitudinal axis Z by multiple successive tool engagements with the workpiece. This is, of course, also true when only a single profile forming head is provided, or when tool engagement is performed from only one side, or in any case when multiple tools are not used.

[0172] Such axial motion is shown in Figure 5 by large, solid black arrows.

[0173] For this purpose, a drive unit AZ for axial forward movement can be provided. During the machining process, it can be advantageous to be able to advance the tool radially, and therefore perpendicular to the longitudinal axis Z. This is because the profile gap being formed becomes deeper as the number of engagements increases. This is true even when only a single profile forming head is provided, or when tool engagement occurs from only one side, or in any case when it is not performed simultaneously by multiple tools.

[0174] Such radial feeding motion is represented in Figure 5 by an open arrow labeled L2. This can be performed along an axis that extends perpendicular to the longitudinal axis and is parallel to the plane traced by the rotational motion of the tool holder.

[0175] For this purpose, a drive unit A2 for radial feeding can be provided. Due to radial feeding, the trajectory or motion path of the tool holder arises from a superposition of circumferential motion U and (linear) radial feeding motion, as schematically shown in Figures 6A to 6C.

[0176] Here, Figure 6A represents the circular path U of the tool holder. Figure 6B shows the radial feed motion L2.

[0177] Figure 6C shows the trajectory T of the tool holder resulting from the superposition of the orbital motion U and the radial feed L2. Here, in practice, the distances between the nearly circular trajectory components can be much smaller than those clearly shown in Figure 6C.

[0178] Figure 7 shows details of the apparatus 100 having two profile molding heads, each having three tool holders 5a1, 5a2, 5a3 and 5b1, 5b2, 5b3, each having two tools 2a1, 2a1' and 2a2, 2a2', etc.

[0179] By providing several tool holders 5a1, 5a2, ... (in some cases, per profile forming head), several engagements can be made for each orbit of the circumferential body, thereby enabling rapid machining and thus faster profile creation.

[0180] By providing several tools for each tool holder, their service life can be extended, thus enabling longer, uninterrupted profile forming. For example, the second synchronization device S5 (see Figure 1) can be configured such that, given n tools for each tool holder, in each case, after the orbit of the orbital body 8 at a specific position along the orbital path U (see Figure 1) of the tool holder 5 (e.g., where engagement with tool 1 is completed), the tool axis of each tool has an azimuth orientation that differs by 306° / n from its azimuth position at the start of the orbit. This difference is not 360° or a multiple of 360°, but may be a multiple of 360° / n.

[0181] Furthermore, Figure 7 shows that by the method described herein, a profile can also be formed between two profile defining structures, for example, between two workpiece shoulders 13, 13', and each profile can reach close to the profile defining structure.

[0182] Figure 8 shows a profile body 1p having a profile P that can be produced by the method or apparatus described, in a cross section perpendicular to the longitudinal axis Z. The profile formation comprises a number of profile gaps pl. Each of these profile gaps pl is produced by a series of engagements of one or more tools 2, each having an active region 21 having a shape essentially corresponding to the shape of the profile gap pl being produced, in the cross section shown in Figure 8.

[0183] The profile body 1p is a hollow component that sits on a profile-formed mandrel 6 on the outside and has shoulder portions 13 that protrude outward. By using the profile-formed mandrel 6, this method can not only form the outer profile but also form the inner profile at the same time.

[0184] With respect to solid or hollow parts seated on a non-profile mandrel, the outer profile can be formed without simultaneously forming the inner profile.

[0185] Furthermore, it is possible to create internal teeth on a hollow component without forming an external profile on the hollow component. This is shown in Figure 9.

[0186] Figure 9 shows details of workpiece 1, seated on a mandrel 6 with an outwardly profiled shape, in a cross section perpendicular to the longitudinal axis, and about to be machined in the manner described by tool 2. Machining will shape the material of workpiece 1 into a profiled gap 6p. Tool 2 has a wide active area.

[0187] Figure 10 shows, as an example, that in a cross-section including the longitudinal axis Z, the outer surface of the machining area 11 of the tool 1 does not need to be cylindrical, but may be conical, for example, as shown.

[0188] Figure 11 shows, as an example, that the outer surface 11a of the machined area 11 of the workpiece 1 does not necessarily have to be rotationally symmetric in a cross-section perpendicular to the longitudinal axis Z, and may be polygonal, for example, as shown. Figure 11 shows a case where the outer surface 11a has six subsurfaces, but it is also possible to imagine an outer surface 11a with a very large number of subsurfaces. In the relevant machined area, the workpiece 1 may be, for example, prismatic.

[0189] Figure 12 shows an example of a workpiece 1 or profile body 1p having two axially spaced profile defining structures 13, 13' projecting radially outward. A profile P having a profile gap pl generated by the described method reaches near these.

[0190] The profile defining structure may also be oriented radially inward relative to adjacent portions of the machining area. Figure 13 shows an example of this, where the profile defining structure 13 at one end of the machining area 11 is oriented radially inward, and the profile defining structure 13' at the other end of the machining area 11 is oriented radially outward.

[0191] Figure 14 illustrates, as an example, that the machining area 11 does not necessarily need to be defined on one or both sides by profile forming the defining structure. What is shown is the profile body, in which case the ends of the machining area 11 are not adjacent to the profile defining structure.

[0192] Figure 15 shows, as an example, that the profile defining structure 13 of workpiece 1 is not necessarily rotationally symmetric. In the illustrated example, several workpiece protrusions are provided that project radially outward, and these are located at different azimuthal angles.

[0193] Figure 16 shows a workpiece 1 or profile body 1p having a profile in which the profile gap 1p is unevenly distributed in the azimuthal direction in a cross section perpendicular to the longitudinal axis L. While a uniformly distributed profile gap over the circumference is preferable for many applications, there are applications where an irregular arrangement of the profile gap pl in the azimuthal direction is advantageous.

[0194] Naturally, a single workpiece can have two or more different machining areas, which may be spaced apart axially, for example, and in either case, profiles may be provided as described herein.

[0195] In the examples shown in Figures 1, 5, and 7, the plane perpendicular to the tool axis Q includes the longitudinal axis Z. However, this is only one option. As already mentioned above, this option may be particularly useful when straight teeth are manufactured and the workpiece is stationary or rotates only slowly during engagement.

[0196] However, as schematically shown in Figure 17, a plane perpendicular to the tool axis enclosing the pivot angle δ (not equal to 0 degrees) with respect to the longitudinal axis can also be considered. This may be useful, for example, for forming obliquely extending profiles such as oblique teeth, or when the workpiece 1 rotates during tool engagement, such as when the workpiece 1 or workpiece holder rotates at a constant rotational speed. In particular, as shown in Figure 17, the (pivoted) tool axis Q' can pivot relative to the vertically aligned tool axis Q in a direction parallel to the longitudinal axis Z. In other words, the non-pivoted tool axis Q, together with the pivoted tool axis Q', is pivoted so as to lie in a plane parallel to the longitudinal axis Z. The plane referred to in Figure 17 is the plane of the drawing. The plane perpendicular to the pivoted tool axis Q' is represented by a dashed line in Figure 17, and since the pivoted tool axis Q also encloses the pivot angle δ with respect to the non-pivoted tool axis Q, the longitudinal axis encloses the pivot angle δ. The magnitude of the pivot angle δ may depend, for example, on the angle of the profile or the rotational speed of the workpiece or workpiece holder during engagement.

[0197] For example, the profile forming head can be pivoted so that the tool axis Q, the rotation axis W (of the tool holder), and the circumferential axis V can pivot simultaneously.

[0198] If the tool axis Q, rotation axis W, and orbital axis V are parallel to each other, then, for example, they can all pivot around the same pivot angle δ. A plane perpendicular to the tool axis Q is also perpendicular to the rotation axis W and orbital axis V due to their relative parallelism.

[0199] As already explained above, the method described herein can also enable the forming of profiles that require a great deal of force for this purpose, and nevertheless, it is possible to form the profile close to the profile defining structure (e.g., the shoulder of the workpiece).

Claims

1. A method for manufacturing a profile body (1p) on which a profile (P) is provided, by cold working a workpiece (1) having a longitudinal axis (Z) and an outer surface (11a) in which a profile (P) is incorporated within a machining area (11), wherein the workpiece (1) undergoes rotational motion (R1) about the longitudinal axis (Z) and is machined by a first tool (2) in a number of sequentially performed reshaping engagements in which the first tool (2) contacts the machining area (11), the first tool (2) is held by a first tool holder (5; 5a1), and the first tool holder (5; 5a1, ...) - The first tool holder (5; 5a1, ...) is mounted on a rotating body (8) so as to be rotatable about the axis of rotation (W), and is driven to perform rotational motion (R5) about the axis of rotation (W), and the term azimuth angle used below is defined by the axis of rotation (W), - Driven to perform a circular motion (R8) by the aforementioned circular body (8), - The rotational motion (R1) of the workpiece (1) is synchronized with the circumferential motion (R8) of the first tool holder (5; 5a1, ...). - The rotational motion (R5) of the first tool holder (5; 5a1, ...) is synchronized with the circumferential motion (R8) of the first tool holder (5; 5a1, ...). - A method in which the first tool (2) is mounted on the first tool holder (5; 5a1, ...) so as to be rotatable about a first tool axis (Q) different from the rotation axis (W), and in particular is mounted so as to be rotatable, and in particular the first tool axis (Q) is away from the rotation axis (W).

2. - The rotational motion (R1) of the workpiece (1) is synchronized with the circumferential motion (R8) of the first tool holder (5; 5a1, ...) so that several of the reshaping engagements occur at each of several different positions distributed around the circumference of the workpiece (1). The method according to claim 1, wherein the rotational motion (R5) of the first tool holder (5; 5a1, ...) is synchronized with the circumferential motion (R8) of the first tool holder (5; 5a1, ...) such that the first tool (2) passes through the same azimuthal orientation (φ) for each of the reshaping engagements.

3. The method according to claim 1 or 2, wherein the circulating body (8) performs a rotation (R8') about the axis of the circulating body (V), and the axis of the circulating body (V) and the axis of rotation (W) are aligned parallel to each other.

4. The method according to claim 1 or 2, wherein the first tool (2) comprises an active region (21) that is rotationally symmetric with respect to the first tool axis (Q), and in particular the first tool (2) is embodied as a roller.

5. The method according to claim 1 or 2, wherein the rotational motion (R5) of the first tool holder (5; 5a1, ...) is synchronized with the orbital motion (R8) of the first tool holder (5; 5a1, ...) by a planetary gear (40).

6. The method according to claim 5, wherein the planetary gear (40) comprises a ring gear (41) and a planetary gear (45) that travels within the ring gear (41), and the planetary gear (45) is part of the first tool holder (5; 5a1,...) and together with it performs the rotational motion (R5).

7. The method according to claim 1 or 2, wherein the workpiece is simultaneously machined by the second tool (2b) in a number of sequentially performed reshaping engagements in which the second tool (2b) contacts the workpiece (1), in particular each of the sequentially performed reshaping engagements of the second tool (2b) is performed at a position of the workpiece (1) opposite to the position of the workpiece (1) with respect to the longitudinal axis (Z) in which the reshaping engagements of the first tool (2a) are simultaneously performed, in particular the first tool (2a) and the second tool (2b) are embodied as rollers.

8. The method according to claim 1 or 2, wherein the workpiece is further machined by the further tools (2a2, 2a1') in a number of sequentially performed reshaping engagements in which the further tools (2a2, 2a1) contact the workpiece (1), and in particular, the tool holders (5; 5a2, ...) that hold the further tools (2a1') perform the same circumferential motion (R8) as the tool holders (5; 5a1, ...) described above, and the further tool holders (5; 5a2) are identical to or different from the tool holders (5; 5a1, ...) described above, and in particular, the first tool (2a) and the further tools (2a2, 2a1') are embodied as rollers.

9. The method according to claim 8, wherein the further tool (2a1') is held by the same tool holder (5a1) as the first tool (2;2a1), and in particular the further tool (2a1;2a1') is mounted on the tool holder (5a1) so as to be rotatable about a further tool axis different from the rotation axis (W) and the first tool axis (Q), and in particular the further tool axis is spaced apart in the azimuthal direction from the first tool axis (Q), and in particular the first tool axis (Q), the further tool axis and the rotation axis (W) are aligned perpendicular to a common plane.

10. The method according to claim 8, wherein a second tool holder (5a2) is provided, and unlike the first tool holder (5a1), the second tool holder holds the further tool (2a2) so as to be rotatable about the further tool axis, the circumferential motion of the first tool holder and the second tool holder traces the same circumferential path (U), in particular the further tool (2a2) is mounted on the second tool holder (5a2) so as to be rotatable about a further tool axis different from the axis of rotation of the second tool holder, in particular the first tool axis (Q), the further tool axis and the axis of rotation (W) are aligned perpendicular to a common plane.

11. An apparatus (100) for manufacturing a profile body (1p) having a profile (P) formed by cold working a workpiece (1), wherein the apparatus (100) is - A workpiece holder (10) that is rotatable about its longitudinal axis (Z) for holding the workpiece (1), - A drive device (A1) for generating rotational motion (R1) of the workpiece holder (10) about the longitudinal axis (Z), - Orbital body (8), - A first tool holder (5; 5a1) for holding a first tool (2a; 2a1), which is attached to the circumferential body (8) so as to be rotatable about the axis of rotation (W) of the first tool holder (5; 5a1), - A drive device (A5) for generating rotational motion (R5) of the first tool holder (5; 5a1) about its axis of rotation (W), - A drive device (A8) for generating the motion of the circulating body (8), wherein the drive device (A8) is capable of driving the first tool holder (5; 5a1) to perform circulating motion (R8), - A first synchronization device (S1) for synchronizing the rotational motion (R1) of the workpiece holder (10) with the circumferential motion (R8) of the first tool holder (5; 5a1), - A second synchronization device (S5) for synchronizing the rotational motion (R5) of the first tool holder (5; 5a1) with the circumferential motion (R8) of the first tool holder (5; 5a1), The apparatus comprising a first tool holder (5; 5a1) having a first rotating bearing for receiving the first tool (2; 2a1), the first rotating bearing defining a first tool axis (Q) different from the rotation axis (W) of the first tool holder (5; 5a1), thereby the first tool (2; 2a1) being rotatable, in particular rotatable, about the first tool axis (Q).

12. The first tool (2; 2a1) is mounted on the first rotary bearing so as to be rotatable about the first tool axis (Q), and in particular the first tool (2; 2a1) is, - comprising an active region (21) that is rotationally symmetric with respect to the first tool axis (Q), and / or - The apparatus (100) according to claim 11, which is materialized as a roller (2; 2a1).

13. The apparatus (100) according to claim 11 or 12, further comprising a drive device (AZ) for generating motion of the workpiece holder (10) parallel to the longitudinal axis (Z).

14. The apparatus (100) according to claim 11 or 12, comprising a planetary gear (40) which is a component of the second synchronous device (S5) and / or a component of the drive device (A5) for generating rotational motion (R5) of the first tool holder (5; 5a1) about the rotation axis (W).

15. The apparatus according to claim 11 or 12, wherein the circumferential body (8) is attached to the profile molding head (3), and the apparatus (100) includes a drive unit (A2) for moving the profile molding head (3) toward the longitudinal axis (Z).

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